Linearly easy-to-rupture thermoplastic resin film, and method and device for manufacturing the resin film

ABSTRACT

A method for forming substantially parallel linear scratches on a thermoplastic resin film, comprising bringing the film into sliding contact with a means having a lot of fine projections for forming linear scratches, and pressing the film onto the linear-scratch-forming means from the opposite side of the linear-scratch-forming means by a film-pressing means, in a region in which the film is in sliding contact with the linear-scratch-forming means.

FIELD OF THE INVENTION

The present invention relates to a thermoplastic resin film easy tostraight tear in one direction, and a method and apparatus for producingsuch a film.

BACKGROUND OF THE INVENTION

In recent progress of barrier-free items, easy opening is considered tobe an important function for wrapping films. Typical methods for makingthe wrapping bags easily openable include a method of providing thewrapping bags with cutting-start points such as V-shaped notches, etc.in their edge portions (heat-sealing portions), and methods needing nocutting-start points such as a magic cut method, a fancy cut method anda method of providing the wrapping bags with fine pores.

The magic cut and the fancy cut comprise providing the wrapping bagswith fine scratches in their edge portions and bending portions in placeof notches. However, even with the magic cut or the fancy cut, it hasbeen difficult to open the wrapping bags straight in directions notaligned with the molecular orientation of plastic films. Further, whencut lines progress in conventional easy-to-open wrapping bags beyondtheir edge portions to regions in which contents are included, the cutlines are likely to unintentionally go toward the regions havingcontents even though plastic films for the bags have molecularorientation, resulting in falling, dropping or scattering of thecontents.

Working for making a plastic film porous (porous working) is to form alot of fine penetrating or non-penetrating pores on the entire surfaceof the film. Thus, wrapping bags of films subjected to the porousworking can be opened from any position without notches regardless ofthe directions of the films. Accordingly, even if an opening operationis temporarily stopped, the bags can be opened to the end. However,because films for wrapping food, etc. are required to havemoistureproofness, the film subjected to the porous working should belaminated as an outermost film.

JP 2002-80705 A discloses an easy-to-tear, biaxially stretched polyesterfilm, which can be easily torn straight. However, when used forapplications of wrapping films requiring moistureproofness, thebiaxially stretched polyester films should not be used alone butlaminated with polyolefin films, etc., to provide wrapping films.

Vapor-deposited transparent films are widely used as gas-barrier filmsto wrap food, medicine, high-precision electronic parts, etc. However,because the vapor-deposited transparent films are composed ofthermoplastic resin films vapor-deposited with metals, metal oxides,etc. and coated with resins, they have insufficient easy-to-tearcharacteristics even though the plastic base films have easy-to-tearcharacteristics.

For instance, cut tapes are attached to wrapping films for triangularrice balls sold at convenience stores and the like to enable cutting ina strip shape. To adhere the cut tapes to the films, transfer methodsare usually used. As a result, the films cannot be moved at a high speedin the production of the wrapping films, resulting in low productivityand high production cost.

OBJECTS OF THE INVENTION

Accordingly, an object of the present invention is to provide aninexpensive thermoplastic resin film easily torn straight in onedirection regardless of the orientation of the original film, free fromthe above-mentioned defects of the conventional films.

Another object of the present invention is to provide a method forproducing such a film.

A further object of the present invention is to provide an apparatus forproducing such a film.

SUMMARY OF THE INVENTION

As a result of intensive research in view of the above objects, theinventors have found that a thermoplastic resin film havingsubstantially parallel linear scratches at least on one surface haseasy-to-straight-tear characteristics, and that the linear scratches areformed by a linear-scratch-forming means such as a roll, a plate, etc.with a lot of fine projections on the surface, which is in slidingcontact with the film at a proper pressure.

Thus, the easy-to-straight-tear thermoplastic resin film of the presentinvention has substantially parallel linear scratches formed at least onone surface, so that it is easily torn straight from any point along thelinear scratches.

The depth of the linear scratches is preferably 1 to 40% of thethickness of the easy-to-straight-tear thermoplastic resin film. It ispreferable that the depth of the linear scratches is 0.1 to 10 μm, thatthe width of the linear scratches is 0.1 to 10 μm, and that theintervals of the linear scratches are 10 to 200 μm.

The easy-to-straight-tear thermoplastic resin film of the presentinvention may further have a lot of fine penetrating and/ornon-penetrating pores uniformly. The easy-to-straight-tear thermoplasticresin film of the present invention may be a single-layer film or alaminate film. The laminate film preferably has at least one film layerhaving the linear scratches, and a sealant film layer.

The production method of the easy-to-straight-tear thermoplastic resinfilm of the present invention comprises bringing the film into slidingcontact with a means having a lot of fine projections for forming linearscratches, and pressing the film onto the linear-scratch-forming meansfrom the opposite side of the linear-scratch-forming means by afilm-pressing means, in a region in which the film is in sliding contactwith the linear-scratch-forming means, whereby substantially parallellinear scratches are formed on the film.

A roll or plate having a lot of hard fine particles on its surface ispreferably used as the linear-scratch-forming means. The fine particlesare preferably particles having a Mohs' hardness of 5 or more,particularly fine diamond particles.

In one preferred embodiment of the present invention, the film-pressingmeans is an air-blowing means. Air blowing makes it possible to apply asubstantially uniform pressure onto the film surface in sliding contactwith the linear-scratch-forming means. The pressure of an airflow blownonto the film is preferably 0.05 to 5 kgf/cm². Preferable as anair-blowing means is a blower or a nozzle.

In another preferred embodiment of the present invention, thefilm-pressing means is a brush brought into sliding contact with thefilm. The brush preferably has hairs having a recovery-from-bendingratio of 70% or more, a diameter of 0.1 to 1.8 mm, and a length of 1 to8 cm. The brush hairs brought into sliding contact with the film have adensity of 100 to 500/cm² on the brush-sliding surface. The brush ispreferably in sliding contact with the film at a pressure of 0.01 to 5kgf/cm² on the brush-sliding surface.

The outer diameter of the roll is preferably 2 to 20 cm. A tension of0.01 to 5 kgf/cm (width) is preferably applied to the film in slidingcontact with the linear-scratch-forming means. The moving speed of thefilm is preferably 10 to 500 m/minute.

In a further preferred embodiment of the present invention, the linearscratches are formed in the film-moving direction by the roll or plate,whose position is fixed with respect to the width direction of the film.It is preferable that the rotation axis of the roll is parallel with thewidth direction of the film, and that the roll is rotated at a lowerperipheral speed than the moving speed of the film in an oppositedirection to the moving direction of the film. The peripheral speed ofthe roll is preferably 1 to 50 m/minute. The roll is preferably longerthat the film width to have contact with the film over its entire width.

In a still further preferred embodiment of the present invention, anendless pattern belt longer than the width of the film comprises smallrolls or plates having a lot of hard fine particles on the surface inparallel. The endless pattern belt is arranged in the width direction ofthe film such that each small roll or plate can be in sliding contactwith the film. The endless pattern belt is rotated such that the smallrolls or plates are in sliding contact with the continuous film to formlinear scratches on the film slantingly to the moving direction of thefilm. The film-pressing means is an endless brush comprising a largenumber of hairs on an endless belt, which is longer than the width ofthe film; the endless brush being disposed in parallel with the endlesspattern belt via the film. The endless brush is preferably rotated suchthat the direction of the hairs moving in sliding contact with the filmis opposite to the direction of the endless pattern belt moving insliding contact with the film, whereby the brush hairs are continuouslyin sliding contact with the film.

In a still further preferred embodiment of the present invention, atleast two rolls or plates each having an axial direction in the widthdirection of the film are arranged in the moving direction of the film,and vertically movable guide means for independently moving the rolls orplates are arranged in the width direction of the film, each roll orplate slidably moving on the film from one end to the other, and beingrepeatedly subjected to a cycle of moving away from the film afterreaching the other end and returning to the original position, duringwhich the movement of the rolls or plates is controlled such that atleast any one of rolls or plates is always in sliding contact with thefilm over its entire width, whereby linear scratches are formed on thefilm slantingly to its moving direction. The rolls are preferablyrotated at a lower peripheral speed than the moving speed of the film inan opposite direction to the moving direction of the film.

In a still further preferred embodiment of the present invention, atleast two roll trains each comprising small rolls having a large numberof fine hard particles on the surfaces, which are mounted to supports inparallel, are arranged in the width direction of the film; andvertically movable guide means for independently moving the roll trainsare arranged in the width direction of the film; each roll trainslidably moving on the film from one end to the other, and beingrepeatedly subjected to a cycle of moving away from the film afterreaching the other end and returning to the original position, duringwhich the movement of the roll trains is controlled such that at leastany one of the roll trains is always in sliding contact with the filmover its entire width, whereby linear scratches are formed on the filmslantingly to its moving direction. The axial direction of each smallroll in the roll train is preferably substantially in alignment with thelongitudinal direction of the film.

In a still further preferred embodiment of the present invention, anendless pattern belt comprising small rolls or plates having a largenumber of fine hard particles on the surface in parallel, which arelonger than the width of the film, is arranged slantingly to its movingdirection such that each small roll or plate can be in sliding contactwith the film on the film, and the endless pattern belt is rotated in anupstream direction of the film to continuously bring the small rolls orplates into sliding contact with the film, whereby the linear scratchesare formed on the film substantially in its width direction. Thefilm-pressing means is an endless brush comprising a large number ofhairs on an endless belt, which is longer than the width of the film,the endless brush being arranged in parallel with the endless patternbelt via the film, and the endless brush being rotated such that thedirection of the hairs slidably moving on the film is in opposite to thedirection of the endless pattern belt slidably moving on the film,thereby continuously bringing the hairs into sliding contact with thefilm.

In a still further preferred embodiment of the present invention, atleast two rolls each having an axial direction slanting to the movingdirection of the film, and vertically movable guide means forindependently moving the rolls are arranged, each roll slidably movingon the film from one end to the other, and being repeatedly subjected toa cycle of moving away from the film after reaching the other end andreturning to the original position, during which the movement of theroll is controlled such that at least any one of the rolls is always insliding contact with the film over its entire width, whereby the linearscratches are formed on the film substantially in its width direction.Each roll is preferably rotated at a lower peripheral speed than themoving speed of the film in an opposite direction to the movingdirection of the film.

In a still further preferred embodiment of the present invention, atleast two roll trains each comprising small rolls having a large numberof fine hard particles on the surfaces, which are mounted to supports inparallel, are arranged slantingly to the moving direction of the film;and vertically movable guide means for independently moving the rolltrains are arranged in the width direction of the film; each roll trainslidably moving on the film from one end to the other, and beingrepeatedly subjected to a cycle of moving away from the film afterreaching the other end and returning to the original position, duringwhich the movement of the roll trains is controlled such that at leastany one of the roll trains is always in sliding contact with the filmover its entire width, whereby the linear scratches are formed on thefilm substantially in its width direction.

The apparatus for producing an easy-to-straight-tear thermoplastic resinfilm according to the present invention comprises (a) a means for movinga thermoplastic resin film, (b) a linear-scratch-forming means having alot of fine projections, which is brought into sliding contact with thefilm to form substantially parallel linear scratches, and (c) a meansfor pressing the film from the opposite side of thelinear-scratch-forming means in a region in which the film is in slidingcontact with the linear-scratch-forming means.

The linear-scratch-forming means is preferably a roll or a plate havinga lot of hard fine particles on the surface. The fine particles arepreferably particles having a Mohs' hardness of 5 or more, particularlyfine diamond particles.

In one preferred embodiment of the present invention, the film-pressingmeans is an air-blowing means. Preferable as an air-blowing means is ablower or a nozzle. The pressure of an airflow blown onto the film ispreferably 0.05 to 5 kgf/cm².

In another preferred embodiment of the present invention, thefilm-pressing means is a brush brought into sliding contact with thefilm. The brush preferably has hairs having a recovery-from-bendingratio of 70% or more, a diameter of 0.1 to 1.8 mm, and a length of 1 to8 cm. The brush hairs are brought into sliding contact with the film ata density of 100 to 500/cm² on the brush-sliding surface. The brush ispreferably in sliding contact with the film at a pressure of 0.01 to 5kgf/cm² on the brush-sliding surface.

The outer diameter of the roll is preferably 2 to 20 cm. A tension of0.01 to 5 kgf/cm (width) is preferably applied to the film in slidingcontact with the linear-scratch-forming means. The moving speed of thefilm is preferably 10 to 500 m/minute.

In a further preferred embodiment of the present invention, the linearscratches are formed in the film-moving direction by a roll or plate,whose position is fixed with respect to the width direction of the film.It is preferable that the rotation axis of the roll is parallel with thewidth direction of the film, and that the roll is rotated at a lowerperipheral speed than the moving speed of the film in an oppositedirection to the moving direction of the film. The peripheral speed ofthe roll is preferably 1 to 50 m/minute.

In a still further preferred embodiment of the present invention, thelinear-scratch-forming means is an endless pattern belt comprising smallrolls or plates having a large number of fine hard particles on thesurface in parallel, which are longer than the width of the film; eachsmall roll or plate is arranged in the width direction of the film suchthat it can be in sliding contact with the film; and the endless patternbelt is rotated so that the small rolls or plates are continuouslybrought into sliding contact with the film, whereby the linear scratchesare formed on the film slantingly to its moving direction. Thefilm-pressing means is an endless brush comprising a large number ofhairs on an endless belt, which is longer than the width of the film;the endless brush being arranged in parallel with the endless patternbelt via the film; and the endless brush being rotated such that thedirection of the hairs slidably moving on the film is opposite to thedirection of the small rolls or plates slidably moving on the film,whereby the hairs are continuously in sliding contact with the film.

In a still further preferred embodiment of the present invention, theapparatus comprises at least two rolls or plates each having an axialdirection in the width direction of the film, which are arranged inparallel with the moving direction of the film; and vertically movableguide means for independently moving the rolls or plates in the widthdirection of the film; each roll or plate slidably moving on the filmfrom one end to the other, and being repeatedly subjected to a cycle ofmoving away from the film after reaching the other end and returning tothe original position, during which the movement of the rolls or platesis controlled such that at least any one of rolls or plates is always insliding contact with the film over its entire width, whereby the linearscratches are formed on the film slantingly to its moving direction. Therolls are preferably rotated at a lower peripheral speed than the movingspeed of the film in an opposite direction to the moving direction ofthe film.

In a still further preferred embodiment of the present invention, theapparatus comprises at least two roll trains in the width direction ofthe film, each of which comprises small rolls having a large number offine hard particles on the surface and mounted to supports in parallel;and vertically movable guide means for independently moving the rolltrains in the width direction of the film; each roll train slidablymoving on the film from one end to the other, and being repeatedlysubjected to a cycle of moving away from the film after reaching theother end and returning to the original position, during which themovement of the roll train is controlled such that at least any one ofthe roll trains is always in sliding contact with the film over itsentire width, whereby the linear scratches are formed on the filmslantingly to its moving direction. The axial direction of each smallroll in the roll train is preferably substantially in alignment with thelongitudinal direction of the film.

In a still further preferred embodiment of the present invention, thelinear-scratch-forming means is an endless pattern belt comprising smallrolls or plates having a large number of fine hard particles on thesurface in parallel, which are longer than the width of the film; eachsmall roll or plate being arranged slantingly to the moving direction ofthe film such that it can be in sliding contact with the film; and theendless pattern belt being rotated in an upstream direction of the filmsuch that the small rolls or plates are continuously in sliding contactwith the film, whereby the linear scratches are formed on the filmsubstantially in its width direction. The film-pressing means ispreferably an endless brush comprising a large number of hairs on anendless belt, which is longer than the width of the film; the endlessbrush being arranged in parallel with the endless pattern belt via thefilm; and the endless brush being rotated such that the direction of thehairs slidably moving on the film is opposite to the direction of thesmall rolls or plates slidably moving on the film, whereby the hairs arecontinuously in sliding contact with the film.

In a still further preferred embodiment of the present invention, theapparatus comprises at least two rolls each having an axial directionslanting to the moving direction of the film, and vertically movableguide means for independently moving the rolls, each roll slidablymoving on the film from one end to the other, and being repeatedlysubjected to a cycle of moving away from the film after reaching theother end and returning to the original position, during which themovement of the roll is controlled such that at least any one of therolls is always in sliding contact with the film over its entire width,whereby the linear scratches are formed on the film substantially in itswidth direction. Each roll is preferably rotated at a lower peripheralspeed than the moving speed of the film in an opposite direction to themoving direction of the film.

In a still further preferred embodiment of the present invention, thelinear-scratch-forming means is at least two roll trains each comprisingsmall rolls having a large number of fine hard particles on thesurfaces, which are mounted to supports in parallel; the roll trainsbeing arranged slantingly to the moving direction of the film; theapparatus comprising vertically movable guide means for independentlymoving the roll trains in the width direction of the film; and each rolltrain slidably moving on the film from one end to the other, and beingrepeatedly subjected to a cycle of moving away from the film afterreaching the other end and returning to the original position, duringwhich the movement of the roll trains is controlled such that at leastany one of the roll trains is always in sliding contact with the filmover its entire width, whereby the linear scratches are formed on thefilm substantially in its width direction.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic side view showing an example of an apparatus forforming linear scratches on a film in a moving direction thereof;

FIG. 2 is a partial, enlarged plan view showing the direction of acompressed air blown onto a film surface in sliding contact with apattern roll in the apparatus shown in FIG. 1;

FIG. 3 is a partial, enlarged, cross-sectional view showing a film insliding contact with a pattern roll in the apparatus shown in FIG. 1;

FIG. 4(a) is a front view and a right side view showing an example of anozzle;

FIG. 4(b) is a front view and a right side view showing another exampleof a nozzle;

FIG. 4(c) is a schematic view showing the direction of a compressed airblown onto a pattern roll from a nozzle with a hood and the winding of afilm around the pattern roll;

FIG. 5 is a schematic view showing another example of an apparatus forforming linear scratches on a film in a moving direction thereof;

FIG. 6 is a perspective view showing an example of an apparatus forforming linear scratches on a film slantingly to its moving direction;

FIG. 7(a) is a partial, enlarged plan view showing a film in slidingcontact with an endless pattern belt in the apparatus shown in FIG. 6;

FIG. 7(b) is a schematic side view taken from the direction (A) in FIG.7(a);

FIG. 8 is a schematic side view showing another example of an apparatusfor forming linear scratches on a film slantingly to its movingdirection;

FIG. 9 is a partial enlarged plan view showing a film in sliding contactwith a roll train in the apparatus shown in FIG. 8;

FIG. 10(a) is a partial enlarged plan view showing a further example ofan apparatus for forming linear scratches on a film slantingly to itsmoving direction;

FIG. 10(b) is a schematic side view taken from the direction (B) in FIG.10(a);

FIG. 11 is a partial, enlarged plan view showing an example of anapparatus for forming linear scratches on a film perpendicularly to amoving direction thereof;

FIG. 12 is a partial, enlarged plan view showing another example of anapparatus for forming linear scratches on a film perpendicularly to amoving direction thereof;

FIG. 13 is a partial, enlarged plan view showing a further example of anapparatus for forming linear scratches on a film perpendicularly to amoving direction thereof;

FIG. 14(a) is a partial, enlarged plan view showing a still furtherexample of an apparatus for forming linear scratches on a filmperpendicularly to a moving direction thereof;

FIG. 14(b) is a schematic side view taken from the direction (C) in FIG.14(a);

FIG. 15 is a view showing a model of measuring the surface roughness ofthe easy-to-straight-tear thermoplastic resin film of the presentinvention by an AFM;

FIG. 16 is a graph illustrating an AFM image of theeasy-to-straight-tear polyester film in Example 1; and

FIG. 17 is a graph illustrating one cross section of the AFM image ofthe easy-to-straight-tear polyester film in Example 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[1] Method for Forming Linear Scratches

The easy-to-straight-tear thermoplastic resin film of the presentinvention is produced by forming substantially parallel linear scratchesby bringing a continuously running thermoplastic resin film into slidingcontact with a means for forming linear scratches, which has a lot offine projections. The method and apparatus for producing theeasy-to-straight-tear thermoplastic resin film of the present inventionwill be explained below in detail referring to the drawings.

(1) Formation of Linear Scratches on Film in Moving Direction

FIG. 1 is a schematic side view showing an example of an apparatus forforming linear scratches on a film 1 in a moving direction, whichcomprises a roll 2 having a lot of fine projections on the surface(hereinafter referred to as “pattern roll”) as a means for forminglinear scratches, and an air-blowing nozzle 3 as a film-pressing means.A film 1 unwound from a reel 11 having an original film passes betweennip rolls 12 and is brought into contact with a pattern roll 2 to beprovided with linear scratches. The thermoplastic resin film providedwith easy-to-straight-tear characteristics passes through nip rolls 13and guide rolls 14 and 15, and is then wound around a reel 16.

As shown in FIG. 2, the pattern roll 2 is fixed with its rotation axisin parallel with the width direction of the film 1, and longerlongitudinally than the width of the film 1, such that the film 1 is insliding contact with the pattern roll over its entire width.

The nip rolls 12 and 13 disposed upstream and downstream of the patternroll 2 as tension-controlling rolls give tension to the film 1 movingover the pattern roll 2. Further as shown in FIG. 2, the air at apredetermined pressure is blown from a nozzle 3 disposed on the oppositeside of the pattern roll 2 onto the film 1 in sliding contact with thepattern roll 2, so that the film 1 is pressed onto the sliding surface(hereinafter referred to as “roll-sliding surface” unless otherwiseparticularly mentioned) of the pattern roll 2 at a uniform force.Uniform linear scratches are thus formed on the surface of the film.Using the nozzle 3, the film 1 is pressed onto the pattern roll 2, suchthat non-uniform contact with the roll-sliding surface due to the uneventhickness of the film 1 can be suppressed.

Because the pattern roll 2 has a lower peripheral speed than the movingspeed of the film 1, it is preferable to rotate the pattern roll 2 in anopposite direction to the moving direction of the film 1. This canprevent the film from being wrinkled and dust generated by the formationof linear scratches from remaining on the surface of the pattern roll 2,thereby forming linear scratches of proper length and depth. In thepresent invention, the moving speed of the film 1 is preferably 10 to500 m/minute. The peripheral speed of the pattern roll 2 (rotation speedin an opposite direction to the moving direction of the film 1) ispreferably 1 to 50 m/minute.

A usable pattern roll 2 is described, for instance, in JP 2002-59487 A.This pattern roll comprises a lot of fine particles having Mohs'hardness of 5 or more attached to a surface of a metal roll by anelectrodeposition method or by an organic or inorganic binder. The metalroll is made of iron, iron alloys, etc. The metal roll preferably has aplating layer of nickel or chromium. The fine particles having Mohs'hardness of 5 or more are, for instance, cemented carbide particles suchas tungsten carbide, silicon carbide particles, boron carbide particles,sapphire particles, cubic boron nitride (CBN) particles, natural or finesynthetic diamond particles, etc. Fine synthetic diamond particleshaving large hardness and strength are particularly desirable. Theparticle size of the fine particles is properly determined depending onthe depth and width of linear scratches formed. In the presentinvention, the fine particles desirably have a particle size of 10 to100 μm with unevenness of 5% or less. How many fine particles areattached to the roll surface is properly selected such that the formedlinear scratches have desired intervals. To form uniform linearscratches, the fine particles are preferably attached to 50% or more ofthe roll surface. A specific example of the pattern roll 2 may be apattern roll having a lot of fine synthetic diamond particles fixed witha nickel electrodeposition layer to the surface of an iron roll at anarea ratio of 50% or more. The outer diameter of the pattern roll 2 ispreferably 2 to 20 cm, more preferably 3 to 10 cm.

The pattern roll 2 may also be a needle roll having metal needlesembedded in the surface of a metal roll regularly in a lattice patternwith extremely small intervals. In addition to the pattern roll 2, themeans for forming linear scratches may be a pattern plate having manyfine particles having Mohs' hardness of 5 or more as described above onthe surface of a plate body.

FIG. 3 is a partial enlarged cross-sectional view showing the film 1 insliding contact with the pattern roll 2 to form linear scratches. Whenan edge of at least one fine particle 4 on the surface of the patternroll 2 bites the roll-sliding surface, one long linear scratch is formeduntil the edge of the biting fine particle 4 separates away from theroll-sliding surface, because the moving speed of the film 1 is largerthan the peripheral speed of the pattern roll 2 rotating in an oppositedirection as described above.

A nozzle having pluralities of blowing orifices 31 shown in FIG. 4(b)may be used as the air-blowing means, in place of a nozzle having astrip-shaped blowing orifice 31 shown in FIG. 4(a), which is the same asshown in FIGS. 1 to 3. In addition, when a compressed air is blown froma nozzle having a hood 32 covering the pattern roll 2 as shown in FIG.4(c), the compressed air ejected from the blowing orifice 31 is noteasily diffused until it reaches a position at which the film 1 is insliding contact with the pattern roll 2, so that the contact force ofthe film 1 to the pattern roll 2 becomes further uniform on theroll-sliding surface. The pressure of the compressed air flow blown fromsuch air-blowing means is preferably 0.05 to 5 kgf/cm², so that thecontact force of the film 1 to the pattern roll 2 becomes uniform on theroll-sliding surface. The more preferred pressure of the compressed airflow is 0.1 to 2 kgf/cm². The distance from the blowing orifice 31 tothe roll-sliding surface is preferably 10 to 50 cm. The compressed airneeds only uniformly impinge onto a region covering at least a surfaceof the roll. However, if the blowing orifice 31 of the blower or thenozzle were larger than necessary, too much amount of the compressed airis unpreferably needed to obtain a proper gas pressure.

The winding of the film 1 around the fixed pattern roll 2 is preferablyconducted such that an angle θ between the winding direction of the film1 and the unwinding direction of the film 1 is in a range of 60° to 170°as shown in FIG. 4(c). This makes the length and depth of linearscratches easily adjustable. The angle θ is preferably in a range of 90°to 150°. To set the angle θ at a desired value, the vertical position ofthe pattern roll 2 may be changed such that the positional relation ofthe pattern roll 2 to the nip rolls 12 and 13 are properly adjusted.Depending on the way of winding the film 1 around the pattern roll 2 andthe outer diameter of the pattern roll 2, a tension given to the film 1by the nip rolls 12 and 13 and the pressure of a gas ejected from thenozzle 3 may be properly adjusted to obtain linear scratches with thedesired length and depth. In the present invention, a tension (tensionper width) given to the film by the nip rolls 12 and 13 is preferably ina range of 0.01 to 5 kgf/cm width.

In place of the air-blowing means, a brush may be in sliding contactwith the opposite side of the roll-sliding surface, to give a uniformcontact force to the roll-sliding surface. The brush hairs arepreferably movable on a surface of the film 1, on which the brushslides, (hereinafter referred to as “brush-sliding surface” unlessotherwise described), at a lower speed than the moving speed of the film1 in an opposite direction to the moving direction of the film 1. Thus,as shown in FIG. 5, the brush is preferably a rotatable roll brush 5having a lot of hairs radially extending from a brush shaft (rotationshaft), which is longer than the width of the film 1 and fixed inparallel with the width direction of the film 1, such that the brush isin sliding contact with the film 1 over its entire width.

The outer diameter of the rotatable roll brush 5 is preferably 5 to 10cm. The hairs 51 of the rotatable roll brush 5 preferably have arecovery-from-bending ratio of 70% or more, a diameter of 0.1 to 1.8 mm,and a length of 1 to 5 cm. The hairs 51 of the rotatable roll brush 5preferably have a density of 100 to 500/cm² on the brush-slidingsurface. The recovery-from-bending ratio is determined as follows:First, two looped hair fibers having a length of about 26 cm are crossedlike a chain with an upper loop fixed to a hook, and a load (g) as heavyas half of the denier of the hair fiber is applied to a lower loop for 3minutes, and a sample having a length of about 3 cm is cut out of a pairof loops bent like pine leaves, and left to stand for 60 minutes. Anopen angle (θ) of the sample is measured to calculate therecovery-from-bending ratio by the equation of (θ/180)×100 (%). Thoughnot particularly restrictive, the tip ends of the hairs 51 arepreferably substantially in a U-shape or in a tapered shape. Thematerials of the hairs 51 are preferably synthetic resins such aspolypropylene, nylon, acrylic resins, polyethylene, etc., though notparticularly restrictive.

The rotatable roll brush 5 is preferably in sliding contact with thefilm 1 at a pressure of 0.01 to 5 kgf/cm² on the brush-sliding surface.The peripheral speed of the rotatable roll brush 5 (rotation speed in anopposite direction to the moving direction of the film 1) is preferably1 to 50 m/minute.

The length and depth of linear scratches are adjusted to obtain thedesired level of the easy-to-straight-tear characteristics, by properlychanging the moving speed of the film 1, the peripheral speed of thepattern roll 2, the size of the fine diamond particles 4, the outerdiameter of the pattern roll, the gas pressure from the nozzle 3, thepressure of the rotatable roll brush 5, a tension given to the nip rolls12 and 13, etc.

(2) Formation of Slanting Linear Scratches on Film

FIG. 6 shows an example of an apparatus for forming linear scratches onthe film 1 slantingly to the moving direction of the film 1. The samereference numerals are assigned to the same members or portions as inFIG. 1. The apparatus shown in FIG. 6 comprises an endless pattern belt6 comprising a lot of small pattern rolls 21 connected as a means forforming linear scratches, and an endless brush 7 comprising a lot ofhairs 71 implanted to an endless belt as a film-pressing means. FIG.7(a) is a partial enlarged plan view showing the endless pattern belt 6rotating in the width direction of the film 1 in the apparatus shown inFIG. 6, and FIG. 7(b) is a schematic cross-sectional view taken from thedirection (A) in FIG. 7(a).

The endless pattern belt 6 is rotated in the width direction of the film1 as shown in FIGS. 7(a) and 7(b), such that small pattern rolls 21 arein sliding contact with the continuous film 1 to form linear scratcheson the film 1 slantingly to its moving direction. The endless patternbelt 6 is preferably constituted by a larger number of the pattern rolls21 at a high density. The length and outer diameter of each smallpattern roll 21 are both preferably 5 to 10 cm.

The angle of the slanting linear scratches to the moving direction ofthe film can be changed by properly adjusting the peripheral speeds ofthe endless pattern belt 6 and the moving speed of the film 1. Theperipheral speed of the endless pattern belt 6 is usually 1 to 100m/minute. Small pattern rolls 21 are rotated in an opposite direction tothe moving direction of the endless pattern belt 6 on the roll-slidingsurface at a peripheral speed of 1 to 50 m/minute as in the case of thepattern roll 2 described in (1) above.

The endless brush 7 is preferably rotated, such that the direction ofthe hairs 71 moving in sliding contact with the film 1 is opposite tothe direction of the endless pattern belt 6 moving in sliding contactwith the film 1. Thus, the endless brush 7 and the endless pattern belt6 are rotated in the same direction. The hairs 71 of the endless brush 7are preferably as long as 4 to 8 cm. The preferred requirements of thehairs 71 of the endless brush 7 concerning a recovery-from-bendingratio, a diameter, a density on the brush-sliding surface, a tip shapeand a material are the same as those of the rotatable roll brush 5described in (1) above. The pressure of the endless brush 7 on thebrush-sliding surface may be 0.01 to 5 kgf/cm², the same as in therotatable roll brush 5 described in (1) above. The pressure at which theendless brush 7 comes into sliding contact with the film 1 may becontrolled by properly adjusting the vertical position of the endlessbrush 7 by rotating a height-controlling knob 73. The peripheral speedof the endless brush 7 is preferably 1 to 50 m/minute. The peripheralspeed of the endless brush 7 may be controlled by properly adjusting therotation speed of a motor 74. The endless pattern belt 6 and the endlessbrush 7 are preferably longer than the width of the film 1 in theirmoving directions, such that the film 1 is brought into sliding contactwith the endless pattern belt 6 and the endless brush 7 over its entirewidth.

FIG. 8 shows another example of an apparatus for providing the film 1with linear scratches slantingly to the moving direction. The samereference numerals are assigned to the same members or portions as inFIG. 1. The apparatus shown in FIG. 8 comprises a roll train 8 acomprising a lot of small pattern rolls 22 a mounted to a guide rail(support) 81 a in parallel, and a roll train 8 b comprising a lot ofsmall pattern rolls 22 b mounted to a guide rail (support) 81 b inparallel, as means for forming linear scratches, as shown in FIG. 9

Support shafts 91 a and 91 b supporting the pattern rolls 22 a and 22 bare movable up and down, and the roll trains 8 a and 8 b are movablestraight along the guide rails 81 a and 81 b, respectively, in the widthdirection of the film 1. The guide means comprising the support shafts91 a and 91 b movable up and down and the guide rails 81 a and 81 b canindependently move the roll trains 8 a and 8 b in the width direction ofthe film 1. Accordingly, the roll trains 8 a and 8 b move from one endof the film 1 to the other end thereof in a slidably contacting manner,and then separate from the film 1 and return to the original position,and this cycle is repeated. During this cycle, the movement of the rolltrains 8 a and 8 b is controlled such that at least any one of the rolltrains is always in sliding contact with the film 1 over its entirewidth, thereby forming linear scratches on the film slantingly to itsmoving direction. As the guide means, instead of making the supportshafts 91 a and 91 b not movable up and down relative to the guide rails81 a and 81 b, the guide rails 81 a and 81 b may move up and down.

The longitudinal length and outer diameter of each pattern roll 22 a, 22b may be about 5 to 10 cm. Intervals between the adjacent pattern rolls22 a, 22 b are preferably narrower than the width of each pattern roll,such that the pattern rolls are disposed at a high density. Each rolltrain 8 a, 8 b is longer than the width of the film 1.

The apparatus shown in FIG. 8 comprises the same endless brushes 7 a and7 b as in the apparatus shown in FIG. 6 as film-pressing means, and theendless brushes 7 a and 7 b are opposing to the roll trains 8 a and 8 bin parallel via the film 1. Support members 72, 72 supporting theendless brushes 7 a and 7 b are movable up and down. Accordingly, thevertical movement of the endless brush 7 a is controlled such that boththe endless brush 7 a and the roll train 8 a are brought into slidingcontact with the film 1 simultaneously, and the vertical movement of theendless brush 7 b is controlled such that both the endless brush 7 b andthe roll train 8 b are brought into sliding contact with the film 1simultaneously. Thus, a constant contact force is always applied to theroll-sliding surface.

The endless brushes 7 a and 7 b are preferably rotated such that themoving direction of their hairs in sliding contact with the film 1 isopposite to the moving direction of the roll trains 8 a and 8 b insliding contact with the film 1. The preferred requirements of the hairsof the endless brushes 7 a and 7 b concerning a recovery-from-bendingratio, a diameter, a length, a density on the brush-sliding surface, atip shape and a material, and the preferred requirements of the endlessbrushes 7 a and 7 b concerning a pressure onto the brush-sliding surfaceand a peripheral speed may be the same as those of the endless brush 7in the apparatus shown in FIG. 6.

The angle of the slanting linear scratches to the moving direction ofthe film may be changed by properly adjusting the speed of the rolltrains 8 a and 8 b in sliding contact with the film 1 and the movingspeed of the film 1. The pattern rolls 22 a and 22 b are rotated in anopposite direction to the moving direction of the roll trains 8 a and 8b on the roll-sliding surface. Their peripheral speed may be the same asthat of the pattern rolls 2 described in (1) above.

FIGS. 10(a) and 10(b) show another example of an apparatus for forminglinear scratches slantingly to the moving direction of the film 1. Inthis embodiment, two pattern rolls 23 a and 23 b each having a largerlongitudinal length than the width of the film 1 are disposed inparallel in two rows in the moving direction of the film 1. Thelongitudinal length of each pattern roll 23 a and 23 b is preferably 2times the width of the film 1 or more.

Support shafts 92 a and 92 b supporting the pattern rolls 23 a and 23 bare movable up and down, and the pattern rolls 23 a and 23 b are movablestraight along guide rails 82 a and 82 b in the width direction of thefilm 1. The pattern rolls 23 a and 23 b can move independently in thewidth direction of the film 1 by a guide means comprising the verticallymovable 92 a and 92 b and the guide rails 82 a and 82 b. Accordingly,the pattern rolls 23 a and 23 b move from one end of the film 1 to theother end thereof in a slidably contacting manner, and then separatefrom the film 1 and return to the original position, and this cycle isrepeated. During the cycle, the movement of the pattern rolls 23 a and23 b can be controlled such that at least any one of the pattern rollsis always in sliding contact with the film 1 over its entire width,thereby forming linear scratches slanting to the moving direction of thefilm. The angle of the slanting linear scratches to the moving directionof the film can be changed by properly adjusting the sliding speed ofthe pattern rolls 23 a and 23 b and the moving speed of the film 1.

The apparatus shown in FIG. 10 comprises, as film-pressing means,endless brushes 7 a and 7 b movable up and down and opposing the patternrolls 23 a and 23 b in parallel via the film 1 like the apparatus shownin FIG. 8.

Though the apparatuses shown in FIGS. 6 to 10 comprise the endlessbrushes as film-pressing means, they may comprise the air-blowing meansdescribed in (1) above.

(3) Formation of Linear Scratches on Film in Width Direction

FIG. 11 shows an example of an apparatus for forming linear scratches ona film 1 in its width direction. The same reference numerals areassigned to the same members or portions as in FIG. 6. The apparatusshown in FIG. 11 is the same as shown in FIGS. 6 and 7 except that anendless pattern belt 6 is disposed slantingly to the moving direction ofa film (no endless brush shown). Using the apparatus having thestructure shown in FIG. 11, linear scratches can be formed on the film 1in its width direction, by properly adjusting operation conditions suchas the moving speed of the film 1, the angle of the endless pattern belt6 to moving direction of the film 1, the peripheral speed of the patternbelt 6, etc.

FIG. 12 shows another example of an apparatus for forming linearscratches on the film 1 in a width direction. In this embodiment, anendless pattern belt 6 a comprising a lot of small pattern rolls 21 aand an endless pattern belt 6 b comprising a lot of small pattern rolls21 b are disposed symmetrically to the center line 17 of the film 1 as asymmetry axis and slanting to the moving direction of the film. The sameendless brushes (not shown) as in the apparatus shown in FIG. 6 arepreferably disposed as film-pressing means in parallel with endlesspattern belts 6 a and 6 b via a film 1.

Using the apparatus having the structure shown in FIG. 12, linearscratches can be formed on the film 1 in its width direction, byproperly adjusting operation conditions such as the moving speed of thefilm 1, the angles of the endless pattern belts 6 a and 6 b to thecenter line 17 of the film 1, the peripheral speeds of the endlesspattern belts 6 a and 6 b, etc.

FIG. 13 shows another example of an apparatus for forming linearscratches on the film 1 in its width direction. The apparatus shown inFIG. 13 is the same as shown in FIG. 9, except that the same roll trains8 a and 8 b as shown in FIG. 9 are disposed slantingly to the widthdirection of the film 1 (no endless brushes shown). Using the apparatushaving the structure shown in FIG. 13, linear scratches can be formed onthe film 1 in its width direction, by properly adjusting operationconditions such as the moving speed of the film 1, the angles of theroll trains 8 a and 8 b relative to the moving direction of the film 1,the sliding speeds of the roll trains 8 a and 8 b, etc.

FIGS. 14(a) and 14(b) show another example of an apparatus for forminglinear scratches on the film 1 in a width direction. FIG. 14(b) shows aleft side of the apparatus shown in FIG. 14(a) [taken from the direction(C) in FIG. 14(a)]. The apparatus in this embodiment comprises twopattern rolls 24 a and 24 b each having a longitudinal axis slanting tothe moving direction of the film 1. The longitudinal length of eachpattern roll 24 a and 24 b is preferably at least two times the width ofthe film 1 or more.

Support shafts 93 a and 93 b supporting the pattern rolls 24 a and 24 bare movable up and down, and the pattern rolls 24 a and 24 b are movablestraight along guide rails 83 a and 83 b at a predetermined anglerelative to the center line 17 of the film 1. The pattern rolls 24 a and24 b can move independently at a predetermined angle relative to thecenter line 17 of the film 1, by a guide means comprising the verticallymovable 93 a and 93 b and the guide rails 83 a and 83 b. Because thepattern roll 24 b is longer than the pattern roll 24 a, the patternrolls 24 a and 24 b can cross each other during moving in oppositedirections. The pattern rolls 24 a and 24 b thus move from one end ofthe film 1 to the other end thereof in a slidably contacting manner, andseparate from the film 1 and return to the original position, and thiscycle is repeated. Linear scratches can be formed on the film in itswidth direction, by controlling the movement of the pattern rolls 24 aand 24 b such that at least any one of the pattern rolls is always insliding contact with the film 1 over its entire width.

As shown in FIG. 14(b), rotatable roll brushes 5 a and 5 b are movableup and down in parallel, and move as the pattern rolls 83 a and 83 bmove along the roll-sliding surface of the film 1. One of the rotatableroll brushes 5 a and 5 b is longer than the other in a longitudinaldirection, so that they can cross each other during moving in oppositedirections. A contact force is thus always applied to the film 1 insliding contact with the pattern roll 83 a or 83 b. The preferredrequirements of the hairs 51 of the rotatable roll brushes 5 a and 5 bconcerning a recovery-from-bending ratio, a diameter, a length, adensity on the brush-sliding surface, a tip shape and a material may bethe same as those of the rotatable roll brush 5 described in (1) above.

In the apparatuses shown in FIGS. 11 to 14, linear scratches can beformed on the film 1 slantingly to its moving direction, by properlyadjusting operation conditions, etc. Though the apparatuses shown inFIGS. 11 to 14 comprise the endless brushes as film-pressing means, theymay comprise the air-blowing means described in (1) above.

[2] Thermoplastic Resin Film

Though not particularly limited, examples of thermoplastic resin filmsusable for producing the easy-to-straight-tear thermoplastic resin filmof the present invention include single-layer films made of polyolefinssuch as polyethylene and polypropylene; polyesters such as polyethyleneterephthalate, polybutylene terephthalate and polyethylene naphthalate;polyvinyl chlorides; fluororesins; polyamides; polycarbonate;polyimides; polyetheretherketone; polyetherketone; elastomers;polyurethanes; polyethersulfone; polyphenylene sulfide; polyamideimides,etc. The thermoplastic resin films may be stretched monoaxially orbiaxially, if necessary.

The above thermoplastic resin film may be vapor-deposited with metals,metal oxides, etc. or coated with resins to provide vapor-depositedtransparent films. Specific examples thereof include silica-depositedpolyethylene terephthalate films, alumina-deposited polyethyleneterephthalate films, etc.

The above thermoplastic resin film may comprise a layer of commonpolyolefins and a sealant layer of special polyolefins. Specifically,they are low-density polyethylene (LDPE), medium-density polyethylene(MDPE), high-density polyethylene (HDPE), cast polypropylene (CPP),linear-low-density polyethylene (LLDPE), very-low-density polyethylene(VLDPE), ethylene-vinyl acetate copolymers (EVAs), ethylene-acrylic acidcopolymers (EAAs), ethylene-methacrylic acid copolymers (EMAAs),ethylene-ethyl acrylate copolymers (EEAs), ethylene-methylmethacrylatecopolymers (EMMAs), ethylene-methyl acrylate copolymers (EMAs), ionomers(IOs), etc. To further improve moisture resistance and gas barrier, thethermoplastic resin film preferably comprises an intermediate layerformed by an aluminum foil, a silica-deposited polyethyleneterephthalate film, an alumina-deposited polyethylene terephthalatefilm, etc.

In the production of a laminate film, the above thermoplastic resin filmor vapor-deposited transparent film is preferably formed with linearscratches described in [1] above, and then laminated with a sealant filmwith or without the above intermediate film. The lamination may becarried out by a known method, for instance, by extrusion with anadhesive layer therebetween. The adhesive layer is preferably made ofpolyethylene.

The thermoplastic resin film may be a film having a lot of fine pores,which is called “porous film.” Fine pores are preferably formed beforeforming the linear scratches described above. The fine pores may bepenetrating or non-penetrating the thermoplastic resin film. The finepores preferably have an average opening diameter of 0.5 to 100 μm, andthey exist at a density of about 500/cm² or more. The upper limit of thedensity of the fine pores is not particularity restricted as long astechnically possible. In the production of the laminate film, thesealant film may be formed with a lot of fine pores described above, ifnecessary, to improve the easy-to-tear characteristics of the laminatefilm.

To form the fine pores on the thermoplastic resin film, the methodsdisclosed in Japanese Patent 2,063,411 and JP 2002-059487 A, forinstance, may be used. In the method for producing a long porous sealantfilm disclosed in Japanese Patent 2,063,411, a long sealant film iscaused to pass between a first roll having fine particles with sharpedges and a Mohs' hardness of 5 or more on the surface (the same as thepattern roll 2 described in [1] (1) above), and a second roll having asmooth surface, with pressure applied to the film passing therebetweenadjusted uniform over its entire width in contact with the roll, to forma lot of penetrating or non-penetrating pores having a diameter of 50 μmor less at a density of 500/cm² or more on the long sealant film withsharp edges of a lot of particles on the first roll surface.

[3] Easy-To-Straight-Tearing Thermoplastic Resin Film

Because the easy-to-straight-tear thermoplastic resin film of thepresent invention has a lot of substantially parallel linear scratchesat least on one surface, it can be easily torn straight from any pointalong the linear scratches. It thus has easy-to-straight-tearcharacteristics in one direction regardless of the orientation of theoriginal film. A wrapping bag formed from the easy-to-straight-tearthermoplastic resin film of the present invention can be opened in astrip shape without tapering while keeping a constant width.

The depth of linear scratches on the easy-to-straight-tear thermoplasticresin film is preferably 1 to 40% of the film thickness, to meet bothrequirements of high strength and good easy-to-straight-tearcharacteristics. The linear scratches formed by the method described in[1] above are preferably as deep as 0.1 to 10 μm and as wide as 0.1 to10 μm, and their intervals are preferably 10 to 200 μm.

The method for measuring the depth, width and intervals of the linearscratches will be explained below referring to the drawings. FIG. 15schematically illustrates the cross section of the easy-to-straight-tearthermoplastic resin film of the present invention rectangularly to thelinear scratches, which is taken from an image of surface roughnessmeasured by an atomic force microscope (AFM). The depth of a linearscratch L₁ is a distance d between a reference line P and the bottom ofthe linear scratch L₁. The width of the linear scratch is a distance D₁between intersections P₁ and P₂, at which the reference line P crossesthe walls of the linear scratch. The interval of linear scratches is adistance D₂ between the bottoms of parallel linear scratches L₁ and L₂.

The film having linear scratches in its moving direction (longitudinaldirection) may be used for wrapping bags for stick cookies. Because thewrapping bags formed by the easy-to-straight-tear thermoplastic resinfilm of the present invention having linear scratches in a longitudinaldirection can be opened in a strip shape without tapering while keepinga constant width, the cookies are not damaged. Though wrappings formedby a biaxially stretched polypropylene films (OPP films) for rice balls,etc. are provided with cutting tapes (tear tapes) in alignment with theopening width, the easy-to-straight-tear thermoplastic resin film of thepresent invention having linear scratches in a longitudinal directiondoes not need a tear tape, because it can be opened while keeping theopening width.

The film having linear scratches slanting to its moving direction may beused for wrapping bags of powdery medicine, seasonings for lunch boxes,etc. A wrapping bag formed by the easy-to-straight-tear thermoplasticresin film of the present invention having slanting linear scratches canbe easily torn slantingly in a corner thereof.

The film having linear scratches in a width direction (transversedirection) may be used for stick-shaped wrapping bags of powdery instantfood, etc. Using the easy-to-straight-tear thermoplastic resin film ofthe present invention having linear scratches in a transverse direction,increasingly demanded stick-shaped wrapping bags can be produced at alow cost.

The present invention will be explained in more detail referring toExamples below without intention of restricting the present inventionthereto.

EXAMPLE 1

A polyester (PET) film having a thickness of 12 μm was brought intosliding contact with a 5-cm-diameter pattern roll with fine syntheticdiamond particles having a diameter of 100 μm to produce aneasy-to-straight-tear polyester film having linear scratches in itsmoving direction, under the conditions that the film speed was 50m/minute, that the peripheral speed of the pattern roll rotating in anopposing direction to the film was 10 m/minute, that the pressure of airblown from a nozzle was 1 kgf/cm², and that a tension given to the filmby nip rolls was 0.5 kgf/cm width.

A surface of the resultant easy-to-straight-tear polyester film wasobserved by AFM. FIGS. 16 and 17 are the drawings of AFM images. FIGS.16 and 17 show different portions of the film, and FIG. 17 shows a crosssection of the observed portion. As is clear from FIGS. 16 and 17,linear scratches of 0.1 to 1 μm in depth, 0.5 to 5 μm in width and 10 to50 μm in interval were formed on the polyester film. It is clear thatbecause the linear scratches were formed by scraping by fine syntheticdiamond particles, film portions on both sides of the grooves wereplastically deformed to bulge by pressure when the linear scratches(grooves) were formed.

It was confirmed that the resultant easy-to-straight-tear polyester filmwas torn straight at least in a longitudinal length of an A4 size or so.

Because the easy-to-straight-tear thermoplastic resin film of thepresent invention can be easily torn straight in one directionregardless of the orientation of the original film as described above,it is useful for wrapping bags requiring various types of easy opening.With the method and apparatus for producing the easy-to-straight-tearthermoplastic resin film of the present invention, it is possible toproduce such easy-to-straight-tear thermoplastic resin films at a lowcost.

1. An easy-to-straight-tear thermoplastic resin film havingsubstantially parallel linear scratches formed on at least one entiresurface, whereby it is easily torn substantially straight from any pointalong said linear scratches.
 2. The easy-to-straight-tear thermoplasticresin film according to claim 1, wherein the depth of said linearscratches is 1 to 40% of the thickness of said film.
 3. Theeasy-to-straight-tear thermoplastic resin film according to claim 1,wherein the depth of said linear scratches is 0.1 to 10 μm.
 4. Theeasy-to-straight-tear thermoplastic resin film according to claim 1,wherein the width of said linear scratches is 0.1 to 10 μm.
 5. Theeasy-to-straight-tear thermoplastic resin film according to claim 1,wherein intervals of said linear scratches are 10 to 200 μm.
 6. Theeasy-to-straight-tear thermoplastic resin film according to claim 1,further having a multiplicity of uniformly located fine penetratingand/or non-penetrating pores.
 7. The easy-to-straight-tear thermoplasticresin film according to claim 1, wherein said film is a single-layerfilm or a laminate film.
 8. The easy-to-straight-tear thermoplasticresin film according to claim 7, wherein said laminate film comprises atleast one film layer having said linear scratches, and a sealant filmlayer. 9-10. (canceled)
 11. The method for producing aneasy-to-straight-tear thermoplastic resin film according to claim 64,wherein said fine particles have a Mohs' hardness of 5 or more.
 12. Themethod for producing an easy-to-straight-tear thermoplastic resin filmaccording to claim 11, wherein said fine particles are fine diamondparticles.
 13. The method for producing an easy-to-straight-tearthermoplastic resin film according to claim 64, wherein said pressing isby a film-pressing means comprising an air-blowing means.
 14. The methodfor producing an easy-to-straight-tear thermoplastic resin filmaccording to claim 13, wherein the pressure of an airflow blown ontosaid film is 0.05 to 5 kgf/cm².
 15. The method for producing aneasy-to-straight-tear thermoplastic resin film according to claim 13,wherein air is blown from a blower or a nozzle.
 16. The method forproducing an easy-to-straight-tear thermoplastic resin film according toclaim 64, wherein said pressing is by a film-pressing means comprising abrush brought into sliding contact with said film.
 17. The method forproducing an easy-to-straight-tear thermoplastic resin film according toclaim 16, wherein said brush have hairs having a recovery-from-bendingratio of 70% or more, a diameter of 0.1 to 1.8 mm and a length of 1 to 8cm, and a density of 100 to 500/cm² on the brush-sliding surface. 18.The method for producing an easy-to-straight-tear thermoplastic resinfilm according to claim 16, wherein said brush is in sliding contactwith said film at a pressure of 0.01 to 5 kg/cm² on said brush-slidingsurface.
 19. The method for producing an easy-to-straight-tearthermoplastic resin film according to claim 64, wherein said roll has anouter diameter of 2 to 20 cm.
 20. The method for producing aneasy-to-straight-tear thermoplastic resin film according to claim 64,wherein a tension of 0.01 to 5 kgf/cm width is applied to said film insliding contact with said roll or plate.
 21. The method for producing aneasy-to-straight-tear thermoplastic resin film according to claim 64,wherein the moving speed of said film is 10 to 500 m/minute.
 22. Themethod for producing an easy-to-straight-tear thermoplastic resin filmaccording to claim 64, wherein linear scratches are formed in the movingdirection of said film with the position of said roll or plate beingfixed in the width direction of said film.
 23. The method for producingan easy-to-straight-tear thermoplastic resin film according to claim 22,wherein the rotation axis of said roll is parallel with the widthdirection of said film, and wherein said roll has a lower peripheralspeed than the moving speed of said film and an opposite rotationdirection to the moving direction of said film.
 24. The method forproducing an easy-to-straight-tear thermoplastic resin film according toclaim 23, wherein the peripheral speed of said roll is 1 to 50 m/minute.25. The method for producing an easy-to-straight-tear thermoplasticresin film according to claim 64, wherein an endless pattern beltcomprising small rolls or plates having a large number of hard fineparticles on the surfaces in parallel, which is longer than the width ofthe film, is arranged in the width direction of said film, such thateach small roll or plate can be in sliding contact with said film; andwherein said endless pattern belt is rotated to continuously bring saidsmall rolls or plates into sliding contact with said film, whereby saidlinear scratches are formed on said film slantingly to its movingdirection.
 26. The method for producing an easy-to-straight-tearthermoplastic resin film according to claim 25, wherein said pressing isby a film-pressing means comprising an endless brush comprising a largenumber of hairs on an endless belt, which is longer than the width ofthe film; wherein said endless brush is disposed in parallel with saidendless pattern belt via said film; and wherein said endless brush isrotated to continuously bring said hairs into sliding contact with saidfilm, such that the direction of said hairs slidably moving on said filmis opposite to the direction of said small rolls or plates slidablymoving on said film.
 27. The method for producing aneasy-to-straight-tear thermoplastic resin film according to claim 64,wherein at least two rolls or plates each having an axial direction inthe width direction of said film are arranged in parallel in the movingdirection of said film; wherein vertically movable guide means forindependently moving said rolls or plates in the width direction of saidfilm is provided; wherein each roll or plate is slidably movable on saidfilm from one end to the other; wherein said rolls or plates arerepeatedly subjected to a cycle of moving away from said film afterreaching the other end and returning to the original position; andwherein the movement of said rolls or plates is controlled such that atleast any one of rolls or plates is always in sliding contact with saidfilm over its entire width, whereby said linear scratches are formed onsaid film slantingly to its moving direction.
 28. The method forproducing an easy-to-straight-tear thermoplastic resin film according toclaim 27, wherein said rolls are rotated at a lower peripheral speedthan the moving speed of said film in an opposite direction to themoving direction of said film.
 29. The method for producing aneasy-to-straight-tear thermoplastic resin film according to claim 64,wherein at least two roll trains each comprising small rolls having alarge number of fine hard particles on the surface, which are mounted tosupports in parallel, are arranged in the width direction of said film,said roll trains independently moving along vertically movable guidemeans in the width direction of said film; wherein each roll trainslidably moves on said film from one end to the other, and is repeatedlysubjected to a cycle of moving away from said film after reaching theother end and returning to the original position, during which themovement of said roll trains is controlled such that at least any one ofsaid roll trains is always in sliding contact with said film over itsentire width, whereby said linear scratches are formed on said filmslantingly to its moving direction.
 30. The method for producing aneasy-to-straight-tear thermoplastic resin film according to claim 29,wherein the axial direction of each small roll in said roll trains issubstantially in alignment with the longitudinal direction of said film.31. The method for producing an easy-to-straight-tear thermoplasticresin film according to claim 64, wherein an endless pattern beltcomprising small rolls or plates having a large number of fine hardparticles on the surfaces in parallel, which are longer than the widthof the film, is arranged slantingly to its moving direction such thateach small roll or plate can be in sliding contact with said film onsaid film; and wherein said endless pattern belt is rotated in anupstream direction of said film to continuously bring said small rollsor plates into sliding contact with said film, whereby said linearscratches are formed on said film substantially in its width direction.32. The method for producing an easy-to-straight-tear thermoplasticresin film according to claim 31, wherein said film-pressing means is anendless brush comprising a large number of hairs on an endless belt,which is longer than the width of the film; wherein said endless brushis arranged in parallel with said endless pattern belt via said film;and wherein said endless brush is rotated such that the direction ofsaid hairs slidably moving on said film is opposite to the direction ofsaid small rolls or plates slidably moving on said film, therebycontinuously bringing said hairs into sliding contact with said film.33. The method for producing an easy-to-straight-tear thermoplasticresin film according to claim 64, wherein at least two rolls each havingan axial direction slanting to the moving direction of said film andvertically movable guide means for independently moving said rolls arearranged; wherein each roll slidably moves on said film from one end tothe other, and is repeatedly subjected to a cycle of moving away fromsaid film after reaching the other end and returning to the originalposition, during which the movement of said rolls is controlled suchthat at least any one of said rolls is always in sliding contact withsaid film over its entire width, whereby said linear scratches areformed on said film substantially in its width direction.
 34. The methodfor producing an easy-to-straight-tear thermoplastic resin filmaccording to claim 33, wherein each roll is rotated at a lowerperipheral speed than the moving speed of said film in an oppositedirection to the moving direction of said film.
 35. The method forproducing an easy-to-straight-tear thermoplastic resin film according toclaim 64, wherein at least two roll trains each comprising small rollshaving a large number of fine hard particles on the surfaces, which aremounted to supports in parallel, are arranged on said film slantingly toits moving direction; wherein vertically movable guide means forindependently moving said roll trains in the width direction of saidfilm are-arranged; wherein each roll train slidably moves on said filmfrom one end to the other, and is repeatedly subjected to a cycle ofmoving away from said film after reaching the other end and returning tothe original position, during which the movement of said roll trains iscontrolled such that at least any one of said roll trains is always insliding contact with said film over its entire width, whereby saidlinear scratches are formed on said film substantially in its widthdirection. 36-37. (canceled)
 38. The apparatus for producing aneasy-to-straight-tear thermoplastic resin film according to claim 65,wherein said fine particles have a Mohs' hardness of 5 or more.
 39. Theapparatus for producing an easy-to-straight-tear thermoplastic resinfilm according to claim 38, wherein said fine particles are fine diamondparticles.
 40. The apparatus for producing an easy-to-straight-tearthermoplastic resin film according to claim 65, wherein saidfilm-pressing means is an air-blowing means.
 41. The apparatus forproducing an easy-to-straight-tear thermoplastic resin film according toclaim 40, wherein the pressure of an airflow blown onto said film is0.05 to 5 kgf/cm².
 42. The apparatus for producing aneasy-to-straight-tear thermoplastic resin film according to claim 40,wherein said air-blowing means is a blower or a nozzle.
 43. Theapparatus for producing an easy-to-straight-tear thermoplastic resinfilm according to claim 65, wherein said film-pressing means is a brushbrought into sliding contact with said film.
 44. The apparatus forproducing an easy-to-straight-tear thermoplastic resin film according toclaim 43, wherein said brush has hairs having a recovery-from-bendingratio of 70% or more, a diameter of 0.1 to 1.8 mm and a length of 1 to 8cm, and a density of 100 to 5 kg/cm² on the brush-sliding surface. 45.The apparatus for producing an easy-to-straight-tear thermoplastic resinfilm according to claim 43, wherein said brush is in sliding contactwith said film at a pressure of 0.01 to 5 kg/cm² on said brush-slidingsurface.
 46. The apparatus for producing an easy-to-straight-tearthermoplastic resin film according to claim 65, wherein said roll has anouter diameter of 2 to 20 cm.
 47. The apparatus for producing aneasy-to-straight-tear thermoplastic resin film according to claim 65,comprising a means for applying a tension of 0.01 to 5 kgf/cm width tosaid film in sliding contact with said linear-scratch-forming means. 48.The apparatus for producing an easy-to-straight-tear thermoplastic resinfilm according to claim 65, comprising means to move the film at 10 to500 m/minute.
 49. The apparatus for producing an easy-to-straight-tearthermoplastic resin film according to claim 65, means to form linearscratches in the moving direction of said film with the position of saidrolls or plates fixed in the width direction of the film.
 50. Theapparatus for producing an easy-to-straight-tear thermoplastic resinfilm according to claim 49, wherein the rotation axis of said roll isparallel with the width direction of said film; and wherein said roll isrotated at a lower peripheral speed than the moving speed of the film inan opposite direction to the moving direction of the film.
 51. Theapparatus for producing an easy-to-straight-tear thermoplastic resinfilm according to claim 50, wherein the peripheral speed of said roll is1 to 50 m/minute.
 52. The apparatus for producing aneasy-to-straight-tear thermoplastic resin film according to claim 65,comprising an endless pattern belt comprising small rolls or plateshaving a large number of fine hard particles on the surfaces inparallel, which are longer than the width of the film; wherein eachsmall roll or plate is arranged in the width direction of said film suchthat it is in sliding contact with said film; and wherein said endlesspattern belt is rotated so that said small rolls or plates arecontinuously brought into sliding contact with said film, whereby saidlinear scratches are formed on said film slantingly to its movingdirection.
 53. The apparatus for producing an easy-to-straight-tearthermoplastic resin film according to claim 52, wherein saidfilm-pressing means is an endless brush comprising a large number ofhairs on an endless belt, which is longer than the width of the film;wherein said endless brush is arranged in parallel with said endlesspattern belt via said film; and wherein said endless brush is rotatedsuch that the direction of said hairs slidably moving on said film isopposite to the direction of said small rolls or plates slidably movingon said film, whereby said hairs are continuously in sliding contactwith said film.
 54. The apparatus for producing an easy-to-straight-tearthermoplastic resin film according to claim 65, comprising at least tworolls or plates each having an axial direction in the width direction ofsaid film, which are arranged in parallel with the moving direction ofsaid film; and vertically movable guide means for independently movingsaid rolls or plates in the width direction of said film; wherein eachroll or plate slidably moves on said film from one end to the other, andis repeatedly subjected to a cycle of moving away from said film afterreaching the other end and returning to the original position, duringwhich the movement of said rolls or plates is controlled such that atleast any one of rolls or plates is always in sliding contact with saidfilm over its entire width, whereby said linear scratches are formed onsaid film slantingly to its moving direction.
 55. The apparatus forproducing an easy-to-straight-tear thermoplastic resin film according toclaim 54, wherein said rolls are rotated at a lower peripheral speedthan the moving speed of said film in an opposite direction to themoving direction of said film.
 56. The apparatus for producing aneasy-to-straight-tear thermoplastic resin film according to claim 65,comprising at least two roll trains in the width direction of said film,each of which comprises small rolls having a large number of fine hardparticles on the surfaces and mounted to supports in parallel; andvertically movable guide means for independently moving said roll trainsin the width direction of said film; wherein each roll train slidablymoves on said film from one end to the other, and is repeatedlysubjected to a cycle of moving away from said film after reaching theother end and returning to the original position, during which themovement of said roll train is controlled such that at least any one ofsaid roll trains is always in sliding contact with said film over itsentire width, whereby said linear scratches are formed on said filmslantingly to its moving direction.
 57. The apparatus for producing aneasy-to-straight-tear thermoplastic resin film according to claim 56,wherein the axial direction of each small roll in said roll train issubstantially in alignment with the longitudinal direction of said film.58. The apparatus for producing an easy-to-straight-tear thermoplasticresin film according to claim 65, comprising an endless pattern beltcomprising small rolls or plates having a large number of fine hardparticles on the surface in parallel, which are longer than the width ofthe film; wherein each small roll or plate is arranged slantingly to themoving direction of said film such that it can be in sliding contactwith said film; and wherein said endless pattern belt is rotated in anupstream direction of said film such that said small rolls or plates arecontinuously in sliding contact with said film, whereby said linearscratches are formed on said film substantially in its width direction.59. The apparatus for producing an easy-to-straight-tear thermoplasticresin film according to claim 58, wherein said film-pressing means is anendless brush comprising a large number of hairs on an endless belt,which is longer than the width of the film; wherein said endless brushis arranged in parallel with said endless pattern belt via said film;and wherein said endless brush is rotated such that the direction ofsaid hairs slidably moving on said film is opposite to the direction ofsaid small rolls or plates slidably moving on said film, whereby saidhairs are continuously in sliding contact with said film.
 60. Theapparatus for producing an easy-to-straight-tear thermoplastic resinfilm according to claim 65, comprising at least two rolls each having anaxial direction slanting to the moving direction of said film,vertically movable guide means for independently moving said rolls, anda mechanism for controlling said support member, wherein each rollslidably moves on said film from one end to the other, and is repeatedlysubjected to a cycle of moving away from said film after reaching theother end and returning to the original position, during which themovement of E said roll is controlled such that at least any one of saidrolls is always in sliding contact with said film over its entire width,whereby said linear scratches are formed on said film substantially inits width direction.
 61. The apparatus for producing aneasy-to-straight-tear thermoplastic resin film according to claim 60,wherein each roll is rotated at a lower peripheral speed than the movingspeed of said film in an opposite direction to the moving direction ofsaid film.
 62. The apparatus for producing an easy-to-straight-tearthermoplastic resin film according to claim 65, comprising at least tworoll trains each comprising small rolls having a large number of finehard particles on the surfaces, which are mounted to supports inparallel; wherein said roll trains are arranged slantingly to the movingdirection of said film; wherein said apparatus comprises verticallymovable guide means for independently moving said roll trains in thewidth direction of said film; and wherein each roll train slidably moveson said film from one end to the other, and is repeatedly subjected to acycle of moving away from said film after reaching the other end andreturning to the original position, during which the movement of saidroll trains is controlled such that at least any one of said roll trainsis always in sliding contact with said film over its entire width,whereby said linear scratches are formed on said film substantially inits width direction.
 63. The easy-to-straight-tear thermoplastic resinfilm according to claim 6, wherein said fine pores have an averageopening diameter of 0.5 to 100 μm.
 64. A method for formingsubstantially parallel linear scratches on a thermoplastic resin film,comprising bringing said film into sliding contact with a roll or platehaving a multiplicity of hard fine particles on its surface, andpressing said film onto said roll or plate.
 65. An apparatus formingsubstantially parallel linear scratches on a thermoplastic resin film,comprising (a) a means for moving said film, (b) a roll or a platehaving a multiplicity of fine hard particles on its surface, and (c) afilm-pressing means disposed near said roll or plate, the saidfilm-pressing means being adapted to press the film onto the roll orplate while the film is brought into sliding contact with said roll orplate.